PRESENTATION OUTLINE

Potential areas in power plants for energy saving Waste heat areas & utilization

Energy saving Opportunity in Thermal Power plant

In any thermal plant normally 3040 % fuel energy is converted into electricity and rest is wasted in various processes of generation, distribution or transmission with heat loss as major loss

Energy saving Opportunity in Thermal Power plant

Air and flue gas cycle Furnace Steam cycle Fuel and ash cycle Feed water/condensate cycle CW /ACRW cycle Compressed air system Refrigeration & HVAC Miscellaneous system

Energy saving Opportunity in Thermal Power plant

Air and Flue Gas Cycle Optimising Air Fuel ratio. A 10% drop in excess air amounts to 1% saving of fuel in furnaces Replacement of oversize fans Attending air and flue gas duct leakages

Energy saving Opportunity in Thermal Power plant

Furnace Reduce heat loss through furnace openings. Observations show that a furnace operating at a temp. of 10000C having an open door (1500 mm X 750 mm) results in fuel loss of 10 lit/hr. For a 4000 hrs. furnace operation this translates in to a loss of approx. Rs. 4 lakhs per year.

Energy saving Opportunity in Thermal Power plant

Feed water / steam cycle
Practicing of scoop control instead of p control Optimising of HP/LP heater level Charging of APRDS from CRH Monitoring of recirculation valve passing Installation of VFD on partially loaded drives

Energy saving Opportunity in Thermal Power plant Fuel and Ash Cycle
Proper maintenance of mills and replacement of mill internals Optimum loading of mills Use of high CV coal wherever available Avoiding idle running of conveyers & crushers Use of dry ash evacuation instead of wet ash Optimising ash water ratio

Energy saving Opportunity in Thermal Power plant

Electrical & Lighting system
Optimising voltage level in DTs Reducing voltage of lighting transformers Use of electronic ballast in place of conventional choke saves energy upto 20%. Use of CFL lamp in place of GLS lamp can save energy upto 70%.

Energy saving Opportunity in Thermal Power plant CW/Aux CW System

Isolating standby equipments Improving condenser performance by proper cleaning of tubes and water condition Some innovative measure as polymer coating on pump internals

Energy saving Opportunity in Thermal Power plant

Refrigeration & HVAC
Utilise waste heat of excess steam or flue gases to change over from gas compression to absorption chilling system and save energy costs in the range of 50- 70%. Proper maintenance of equipments as CT , chillers and condensers etc. for proper heat exchange. A 50C decrease in evaporator temp. increases the specific power consumption by 15%. Use of wind turbo exhauster.

Energy saving Opportunity in Thermal Power plant

Compressed Air system

Optimising air discharge pressure Use of screw compressors instead of reciprocating compressors

NATIONAL AND INTERNATIONAL BENCHMARKS

PLANT AUXILIARY POWER CONSUMPTION IS THE MOST IMPORTANT PARAMETER THAT SHOULD BE TAKEN UP AS E. C. ACTIVITY
A BENCHMARK OF APC FOR A 500 MW UNIT WOULD BE AROUND 5% BENCHMARK OF APC FOR A 200 MW UNIT MAY BE TAKEN AS 7% CORRESPONDING BENCHMARK FOR A 660 MW UNIT IN INTERNATIONAL PLANT WOULD BE 3.66%

Energy saving Opportunity in Thermal Power plant

Installation of On Line Energy management system for major drives Installation of back pressure turbine

Certain Startling Facts

Loss of even one drop of oil every second can cost you over 4000 litres a year An uncovered flange is equivalent to leaving 0.6 meter of pipe line un-legged. If a 0.15 m steam pipe diameter has 5 uncovered flanges, there would be a loss of heat equivalent to wasting 5 tons of coal or 3000 litres of oil a year

Certain Startling Facts

Every 4o C rise in inlet air temperature of a compressor results in a higher energy consumption by 1 % to achieve equivalent output For every 250 mm WC pressure drop increase across the suction path due to choked filters etc., the compressor power consumption increases by about 2 % for the same output

Certain Startling Facts

An increase of 5.5o C in the inlet air temperature to the second stage of compressor results in a 2 % increase in the specific energy consumption A reduction in the delivery pressure by 1 bar in a compressor would reduce the power consumption by 6 10 % A leakage from a dia hole from a compresses air line working at a pressure of 7Kg/cm2 can drain almost Rs. 3000 per day.

Certain Startling Facts

Keep compressor valves in good condition by removing and inspecting once every six months. Worn-out valves can reduce compressor efficiency by as much as 50 percent. Consideration should be given to two-stage or multistage compressor as it consumes less power for the same air output than a single stage compressor. If pressure requirements for processes are widely different (e.g. 3 bar to 7 bar), it is advisable to have two separate compressed air systems

Certain Startling Facts

Replacement of metallic or Glass fibre reinforced plastic fan blades with efficient hollow FRP blades, have given resultant fan energy savings of the order of 20-30% and with simple pay back period of 6 to 7 months

Therefore
A systematic and well documented energy audit of any subsystem will give the plant engineer a plan through which he can effectively manage the plants energy system and significantly reduce the plants energy costs

Thank You